Effective discharge of exhaust from submerged combustion melters and methods

ABSTRACT

Submerged combustion methods and systems including a melter equipped with an exhaust passage through the ceiling or the sidewall having an aggregate hydraulic diameter. Submerged combustion burners configured to create turbulent conditions in substantially all of the material being melted, and produce ejected portions of melted material. An exhaust structure including a liquid-cooled exhaust structure defining a liquid-cooled exhaust chamber having a cross-sectional area greater than that of the exhaust stack but less than the melter. The exhaust passage and liquid-cooled exhaust structure configured to maintain temperature and pressure of the exhaust, and exhaust velocity through the exhaust passage and the exhaust structure, at values sufficient to prevent the ejected material portions of melted material from being propelled out of the exhaust structure as solidified material, and maintain any molten materials contacting the first interior surface molten so that it flows down the first interior surface into the melter.

BACKGROUND INFORMATION Technical Field

The present disclosure relates generally to the field of submergedcombustion melters and apparatus, and methods of use, and morespecifically to submerged combustion melters, and methods of operatingsame, particularly for melting glass-forming materials, mineral wool andstone wool forming materials, and other non-metallic inorganicmaterials.

Background Art

A submerged combustion melter (SCM) may be employed to melt glass batchand/or waste glass materials to produce molten glass, or may meltmineral wool feedstock (basalt rock, sometimes referred to as lava rock)to make mineral or rock wool, by passing oxygen, oxygen-enrichedmixtures, or air along with a liquid, gaseous and/or particulate fuel(some of which may be in one or more of the feedstock materials),directly into a molten pool of glass or other material, usually throughburners submerged in a turbulent melt pool. The introduction of highflow rates of products of combustion of the oxidant and fuel into themolten material, and the expansion of the gases during submergedcombustion (SC), cause rapid melting of the feedstock and muchturbulence and foaming. Conventional melters operate primarily bycombusting fuel and oxidant above the molten pool of melt, and are verylaminar in flow characteristics compared to SCMs.

In known SCMs, exhaust exits through one or more exhaust ports in theceiling and/or sidewalls, then is mixed with dissolution air to cool theexhaust gases and convey them to an abatement system such as a baghouse.Improvements were made to this system as described in assignee'sprevious U.S. Pat. No. 8,707,740, including in some embodiments theprovision of a liquid-cooled transition section connecting the exhaustpassage with an air-cooled exhaust section, which then connects to theexhaust stack.

However, additional issues have been identified and innovations made tofurther improve exhaust gas discharge from a submerged combustionmelter. A particular problem has been discovered that as SC burnersoperate, large balloons or envelopes (note—suggest using “balloons” or“envelopes” rather than “bubbles” as there may be confusion of this withfoam bubbles) containing combustion products “pop” after they rise,causing pressure pulses in the SCM and ejected molten masses (“blobs”)traveling upwards. The pressure pulses vary the pressure and exhaustflow rate and can enhance particulate feed carryover (“carryover” is aterm of art, meaning some of the particulate feed is entrained into theexhaust without being melted). In addition, despite the provision of theliquid-cooled transition section as described in the '740 patent, it hasbeen discovered through testing that some of the ejected molten massescan still actually exit the melter and solidify as small solid particles(shot), and in severe cases may cause blockage of SCM exhaust portsand/or negatively affect product homogeneity.

It would be advantageous to take advantage of the aggressive mixing andturbulence in the SCM while minimizing these disadvantages in order toimprove the quality (mainly determined by product homogeneity incomposition and temperature) and the quantity of melt from an SCM.

SUMMARY

In accordance with the present disclosure, innovations have been made tofurther improve exhaust gas discharge from a submerged combustionmelter, maximize mixing of particulate feed materials into molten masswithin a SCM while minimizing or eliminating carryover of particulatefeed materials in SCM exhaust, and minimize or eliminate solidified shotparticles from exiting the melter through the exhaust structure.“Particulate feed materials” may include glass batch or otherparticulate matter (organic or inorganic), fed separately or incombination (mixed, semi-mixed, or agglomerated). SCMs and methodswherein the height of a liquid-cooled exhaust discharge stack above asplash region or splash zone within the SCM is increased are described,some SCM embodiments and methods including strategic placement andsizing of the SCM exhaust gas discharge opening(s), and designs topromote draining of molten material back into the molten mass, whileproducing molten glass and other non-metallic inorganic materials, suchas rock wool and mineral wool.

One aspect of this disclosure is a submerged combustion manufacturingmethod comprising:

melting materials in a submerged combustion melter (SCM) equipped withone or more submerged combustion (SC) burners, the SCM having a length(L) and a width (W), a centerline (C), a midpoint (M), a sidewallstructure having a north side (N) and a south side (S), the sidewallstructure connecting a ceiling and a floor of the SCM, the meltercomprising an exhaust passage through the roof, through the sidewallstructure, or both;

combusting a fuel in the one or more SC burners, the SC burnersdischarging combustion products under a level of the material beingmelted in the melter and creating turbulent conditions in substantiallyall of the material as well as ejected portions of melted material; and

exhausting exhaust material from the melter through an exhaust structurefluidly connecting the exhaust passage with an exhaust stack, theexhaust structure comprising (or consisting essentially of, orconsisting of) a liquid-cooled exhaust structure, the liquid-cooledexhaust structure defining a liquid-cooled exhaust chamber having afirst interior surface, the liquid-cooled exhaust structure configuredto prevent the ejected material portions of melted material from beingpropelled out of the exhaust structure as solidified material, andmaintain any molten materials contacting the first interior surfacemolten so that it flows back down the first interior surface back intothe melter. It is expressly understood that embodiments including only aliquid-cooled exhaust structure fluidly connecting the SCM exhaustpassage or passages with the conventional exhaust stack are describedherein. (By “conventional exhaust stack” is meant the ducting routingexhaust to a baghouse or other environmental compliance units, such asan electrostatic precipitator or cyclone separator).

Certain embodiments may comprise, or consist essentially of, the stepsof the first aspect, and in addition may include exhausting the exhaustmaterial from the liquid-cooled exhaust structure to a gas-cooledexhaust structure fluidly connecting the liquid-cooled exhaust structureand the exhaust stack, the gas-cooled exhaust structure defining agas-cooled exhaust chamber having a second interior surface, thegas-cooled exhaust structure consisting of a metal layer forming thesecond interior surface, the metal layer having one or more gas-cooledexternal surfaces, the gas-cooled exhaust structure devoid of refractoryor other lining. Certain embodiments may comprise, or consistessentially of, or consist of the steps of the first aspect, and inaddition include wherein the exhaust passage is substantially centrallylocated between a feed end and an exit end of the melter, and theexhausting of the exhaust material through the exhaust structurecomprises exhausting the exhaust material substantially centrallybetween the feed end and the exit end of the melter.

Another aspect of the disclosure is submerged combustion manufacturingsystems for carrying out such methods. Other method and systemembodiments, such as detailed herein, are considered aspects of thisdisclosure. Methods and systems of the disclosure will become moreapparent upon review of the brief description of the drawings, thedetailed description of the disclosure, and the claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The manner in which the objectives of the disclosure and other desirablecharacteristics can be obtained is explained in the followingdescription and attached drawings in which:

FIG. 1 is a schematic perspective view, partially in phantom, of a firstembodiment of a submerged combustion manufacturing system in accordancewith the present disclosure;

FIG. 2 is a schematic perspective view, partially in phantom, of asecond embodiment of a submerged combustion manufacturing system inaccordance with the present disclosure;

FIGS. 3 and 4 are schematic perspective and cross-sectional views,respectively, of one embodiment of a gas-cooled exhaust section inaccordance with the present disclosure;

FIG. 5 is a schematic cross-sectional view of one embodiment of aliquid-cooled exhaust section in accordance with the present disclosure;

FIG. 6 is a schematic end elevation view, partially in cross-section, ofa third embodiment of a submerged combustion manufacturing system inaccordance with the present disclosure;

FIG. 7 is a more detailed schematic side elevation view, partially incross-section, of the system illustrated schematically in FIG. 6;

FIG. 8 is a schematic plan view of one melter floor plan in accordancewith the present disclosure; and

FIGS. 9 and 10 are logic diagrams illustrating two methods of thepresent disclosure.

It is to be noted, however, that the appended drawings are schematic innature, may not be to scale, and illustrate only typical embodiments ofthis disclosure and are therefore not to be considered limiting of itsscope, for the disclosure may admit to other equally effectiveembodiments.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to providean understanding of the disclosed systems, apparatus, and methods.However, it will be understood by those skilled in the art that thesystems, apparatus, and methods covered by the claims may be practicedwithout these details and that numerous variations or modifications fromthe specifically described embodiments may be possible and are deemedwithin the claims. For example, wherever the term “comprising” is used,embodiments and/or components where “consisting essentially of” and“consisting of” are also explicitly disclosed herein and are part ofthis disclosure. An example of “consisting essentially of” may be withrespect to the total feed to an SCM: a feed consisting essentially ofparticulate feedstock means there may be a minor portion of feed that isnot particulate feedstock, such as rock used to make rock wool. Anexample of “consisting of” may be a feedstock made up of onlyparticulate feedstock, or only inorganic particulate feedstock. Anotherexample of “consisting essentially of” may be with respect toparticulate feedstock that consists essentially of inorganic feedstock,meaning that a minor portion, perhaps up to 10, or up to 5, or up to 4,or up to 3, or up to 2, or up to 1 wt. percent may be organic. Exampleof methods and systems using the transition phrase “consisting of”include those where only a liquid-cooled exhaust system is used, with nogas-cooled exhaust structure, or vice versa. Another example of methodsand systems where “consisting of” is used may be with respect to absenceof refractory linings in either the liquid-cooled exhaust structure, thegas-cooled exhaust structure, or both. Another example of methods andsystems where “consisting of” is used may be with respect to the exhauststructure consisting of a liquid-cooled exhaust structure, and completeabsence of a gas-cooled exhaust structure. The term “comprising” andderivatives thereof is not intended to exclude the presence of anyadditional component, step or procedure, whether or not the same isdisclosed herein. In order to avoid any doubt, all compositions,systems, and methods claimed herein through use of the term “comprising”may include any additional component, step, or procedure unless statedto the contrary. In contrast, the term, “consisting essentially of”excludes from the scope of any succeeding recitation any othercomponent, step or procedure, excepting those that are not essential tooperability. The term “consisting of” excludes any component, step orprocedure not specifically delineated or listed. The term “or”, unlessstated otherwise, refers to the listed members individually as well asin any combination.

All references to the Periodic Table of the Elements herein shall referto the Periodic Table of the Elements, published and copyrighted by CRCPress, Inc., 2003. Also, any references to a Group or Groups shall be tothe Group or Groups reflected in this Periodic Table of the Elementsusing the IUPAC system for numbering groups. Unless stated to thecontrary, implicit from the context, or customary in the art, all partsand percentages are based on weight and all test methods are current asof the filing date hereof. The acronym “ASTM” means ASTM International,100 Barr Harbor Drive, PO Box C700, West Conshohocken, Pa., 19428-2959USA.

All numbers disclosed herein are approximate values, regardless whetherthe word “about” or “approximate” is used in connection therewith. Theymay vary by 1%, 2%, 5%, and sometimes, 10 to 20%. Whenever a numericalrange with a lower limit, RL and an upper limit, RU, is disclosed, anynumber falling within the range is specifically disclosed. Inparticular, the following numbers within the range are specificallydisclosed: R=RL+k*(RU−RL), wherein k is a variable ranging from 1% to100% with a 1% increment, i.e., k is 1%, 2%, 3%, 4%, 5%, . . . , 50%,51%, 52%, . . . , 95%, 96%, 97%, 98%, 99%, or 100%. Moreover, anynumerical range defined by two R numbers as defined in the above is alsospecifically disclosed.

All U.S. published patent applications and U.S. patents referencedherein are hereby explicitly incorporated herein by reference. In theevent definitions of terms in the referenced patents and applicationsconflict with how those terms are defined in the present application,the definitions for those terms that are provided in the presentapplication shall be deemed controlling. All percentages herein arebased on weight unless otherwise specified.

As explained briefly in the Background, additional issues have beenidentified and innovations made to further improve exhaust gas dischargefrom a submerged combustion melter. A particular problem has beendiscovered that as SC burners operate, large balloons or envelopescontaining combustion products “pop” after they rise, causing pressurepulses in the SCM and ejected molten masses traveling upwards. Thepressure pulses vary the pressure and exhaust flow rate and can enhanceparticulate feed carryover. In addition, despite the provision of theliquid-cooled transition section as described in the '740 patent, it hasbeen discovered through testing that some of the ejected molten massescan still actually exit the melter and solidify as small solid particles(shot), and in severe cases may cause blockage of SCM exhaust portsand/or negatively affect product homogeneity.

Various modifications to previously known SCMs and methods of operatingsame have been discovered that achieve the desired goal of increasedresidence time of the material being melted in the SCM, which iscritical to achieving good quality product, while reducing ejection ofsolidified materials out of the exhaust structure. In particular, theSCMs and methods described herein take advantage of the aggressivemixing and turbulence in the SCM while minimizing the disadvantagesassociated with splashing in order to improve the quality (mainlydetermined by product homogeneity in composition and temperature) andthe quantity of melt from an SCM.

The present disclosure is devoted to improvements to SCM exhauststructures, in particular extending the liquid-cooled portion from amere transition to a major portion of the exhaust structure, or indeedthe entire exhaust structure in some embodiments, except for the ductingleading to the environmental compliance equipment as mentioned herein.Other improvements relate to the position of the exhaust passages in theSCM ceiling or sidewall structure, or both. In previous designs, asdescribed in the '740 patent, we cooled the first 1 ft. section withwater then the next 6 ft. with air due to weight issues with the watercooling and existing steel work. In accordance with the presentdisclosure, the preferred “next generation” design is to justliquid-cool about 8 to about 12 ft. in height before transitioning tothe hood for air inspiration and metal stack leading to theenvironmental compliance equipment. All individual values and subrangesfrom about 8 up to about 12 ft. are included herein and disclosedherein; for example, the liquid-cooled exhaust section height may rangefrom a lower limit of 6.0, 6.5, 7.5, 7.8, 8, 8.5, 9, 10, or 11 ft. to anupper limit of 9, 9.5, 9.7, 10.5, 10.8, 11, 11.2, 11.5, 11.7, 12, 12.3,12.5, 13, or 14 ft. For example, from about 7.5 to about 11.5 ft., orfrom about 9 to about 11 ft., or from about 9.5 to about 10.5 ft. Inembodiments where there is no burner directly under the exhaust passage,a shorter length liquid-cooled exhaust section may be employed, forexample from about 6 to about 10 ft., or from about 7.5 to about 9.5ft., or from about 8 to about 9 ft. The shorter liquid-cooled heightwill be sufficient for higher viscosity molten materials, but for lowerviscosity molten compositions (for example certain molten glasscompositions) perhaps a higher liquid-cooled section may be employed,especially if the SC burners are being aggressively fired.

The larger the throughput of the SCM the larger the exhaust passagecross-section to maintain the exhaust gas velocity below the 25 ft./min.threshold. Depending on the size of the SCM the exhaust passage andliquid-cooled exhaust section would be sized based on the exhaust gasvelocity, assuming the exhaust is all gas and disregarding molten andsolid bodies that may be in the actual exhaust. The exhaust gas velocityis calculated by dividing the volumetric flow rate of the exhaust by thecross-sectional area of the exhaust passage. The volumetric flow rate ofthe exhaust gas may be estimated via simulation before the SCM andsystem are constructed, based on the throughput of material beingmelted, firing rate of burners, heating value and flow rate of fuel, andother parameters familiar to engineers working in the SCM art. Afterconstruction of the system, volumetric flow rate may be measured by oneor more flow meters placed in the liquid-cooled exhaust section. Allindividual values and subranges of exhaust velocity though exhaustpassages from about 25 ft./min. down to about 2.5 ft./min are includedherein and disclosed herein; for example, the exhaust velocity may rangefrom a upper limit of 27, 26, 25.5, 25, 25.7, 24.8, 24, 23.5, 22.9, 20,or 15 ft. to lower limit of 1, 1.5, 2.5, 3, 3.5, 4.0, 4.5, 5.2, 5.5,6.7, 12, 12.3, 12.5, 15, or 21 ft./min. For example, from about 6.7 toabout 27 ft./min., or from about 9 to about 23 ft./min., or from about9.5 to about 15 ft./min.

Whether an SCM is small or large (throughput), it was surprising thatthe height of the liquid-cooled exhaust section should be fairlyconstant as it is the height the SC burners “spit” glass blobs (or othermaterial being melted) upward that is critical. For example, an SCMfiring 2 SC burners with an SCM throughput of 150 lb/hr., an SCM firing6 SC burners with an SCM throughput of 20 tons/day, and a“production-size” SCM firing 8 SC burners in a 45 ton/day unit, theheight of the liquid-cooled exhaust section was similar, only thecross-sectional area of the exhaust passages changed (increased).

Various terms are used throughout this disclosure. The terms “roof” and“ceiling” are used interchangeably. The terms “process” and method” areconsidered interchangeable. “Submerged” as used herein when referencingthe SC burners means that combustion gases emanate from combustionburners or combustion burner panels under the level of the molten glassin a turbulent molten melt region as defined herein; the burners orburner panels may be floor-mounted, wall-mounted, roof-mounted, or inmelter embodiments comprising more than one submerged combustion burner,any combination thereof (for example, two floor mounted burner panelsand one wall mounted burner panel). Burner panels (such as described inassignee's U.S. patent application Ser. No. 14/838,148, filed Aug. 27,2015) may form part of an SCM floor and/or wall structure. In certainembodiments one or more burner panels described herein may form theentire floor. A “burner panel” is simply a panel equipped to emit fueland oxidant, or in some embodiments only one of these (for example aburner panel may only emit fuel, while another burner panel emits onlyoxidant, and vice versa). “SC” as used herein means “submergedcombustion” unless otherwise specifically noted, and “SCM” meanssubmerged combustion melter unless otherwise specifically noted. Theterm “submerged” when referencing particulate feed material inlet portsor distal ends of feed conduits has similar meaning, except that theyare submerged in the splash region rather than the turbulent molten meltregion.

The term “hydraulic diameter” means D_(H)=4A/P, where A is thecross-sectional area, and P is the wetted perimeter of thecross-section. Hydraulic diameter is mainly used for calculationsinvolving turbulent flow, and for calculating Reynolds number, Re=ρuL/μ,where L=D_(H), μ=viscosity, ρ=density, and u=velocity. Secondary flows(for example, eddies) can be observed in non-circular conduits as aresult of turbulent shear stress in the fluid flowing through theconduit experiencing turbulent flow. Hydraulic diameter is also used incalculation of heat transfer in internal flow problems. For a circleconduit, D_(H) equals the diameter of the circle. For a square conduithaving a side length of a, the DH equals a. For a fully filled conduitwhose cross section is a regular polygon, the hydraulic diameter isequivalent to the diameter of a circle inscribed within the wettedperimeter. “Turbulent conditions” means having a Re>4000, or greaterthan 5000, or greater than 10,000, or greater than 20,000 or higher. Thephrase “turbulent conditions in substantially all of the material beingmelted” means that the SC burners and the SCM are configured so thatthere are some regions near the wall and floor of the SCM where thematerial being melted will be in transient or laminar flow as measuredby Re, but the majority (perhaps greater than 51%, or greater than 55%,or greater than 6%, or greater than 65%, or greater than 70%, or greaterthan 75%, or greater than 80% of the material being melted will beexperiencing turbulent flow. Transient flow is defined as 2300<Re<4000,and laminar flow is defined as Re<2300. The phrase “ejected portions ofmelted material” means portions of the material being melted (orcompletely molten material) that actually separate from the splash zoneand travel generally upward toward the SCM ceiling, or toward the SCMwalls above the splash zone, and even up into the exhaust structure,then either solidify or drip back down into the melt, or fall back intothe melt after an arcuate path upward, reaching a maximum, then fallingback into the melt, as in projectile motion.

As used herein the phrase “combustion gases” as used herein meanssubstantially gaseous mixtures comprised primarily of combustionproducts, such as oxides of carbon (such as carbon monoxide, carbondioxide), oxides of nitrogen, oxides of sulfur, and water, as well aspartially combusted fuel, non-combusted fuel, and any excess oxidant.Combustion products may include liquids and solids, for example soot andunburned liquid fuels. “Exhaust”, “melter exhaust”, and “melter fluegas” are equivalent terms and refer to a combination of combustion gasesand effluent from the feedstock being melted, such as adsorbed water,water of hydration, CO₂ liberated from CaCO₃, and the like. Thereforeexhaust may comprise oxygen or other oxidants, nitrogen, combustionproducts (including but not limited to, carbon dioxide, carbon monoxide,NO_(x), SO_(x), H₂S, and water), uncombusted fuel, reaction products ofmelt-forming ingredients (for example, but not limited to, basalt, sand(primarily SiO₂), clay, limestone (primarily CaCO₃), burnt dolomiticlime, borax and boric acid, and the like.

As used herein, unless indicated to the contrary, “feedstock” includes,but is not limited to: glass batch; cullet; and pieces of porous,semi-porous, or solid rock or other non-metallic inorganic material, ororganic material, or mixture of organic and inorganic material.“Particulate feedstock” as used herein means any feedstock having aweight average particle size (APS) that is small, where small is lessthan 1 mm APS. Other size feedstock(s) may simultaneously be fed to theSCMs of this disclosure, for example feedstocks having particle sizeranging from about 1 mm to about 10 cm, or from about 1 cm to about 10cm, or from about 2 to about 5 cm, or from about 1 to about 2 cm. Theonly upper limit on feedstock weight average particle size for theselarger APS feedstocks is the internal diameter of feedstock supplystructure components, such as described in Applicant's U.S. Pat. No.9,643,869, while the lower size limit is determined by angle of flow,flow rate of feedstock, and in those embodiments where heat is exchangeddirectly or indirectly from melter exhaust to the feedstock, flow rateof melter exhaust.

“Oxidant” as used herein includes air, gases having the same molarconcentration of oxygen as air (for example “synthetic air”),oxygen-enriched air (air having oxygen concentration greater than 21mole percent), and “pure” oxygen grades, such as industrial gradeoxygen, food grade oxygen, and cryogenic oxygen. Oxygen-enriched air mayhave 50 mole percent or more oxygen, and in certain embodiments may be90 mole percent or more oxygen.

The term “fuel”, according to this disclosure, means a combustiblecomposition comprising a major portion of, for example, methane, naturalgas, liquefied natural gas, propane, hydrogen, steam-reformed naturalgas, atomized hydrocarbon oil, combustible powders and other flowablesolids (for example coal powders, carbon black, soot, and the like), andthe like. Fuels useful in the disclosure may comprise minor amounts ofnon-fuels therein, including oxidants, for purposes such as premixingthe fuel with the oxidant, or atomizing liquid or particulate fuels. Asused herein the term “fuel” includes gaseous fuels, liquid fuels,flowable solids, such as powdered carbon or particulate material, wastematerials, slurries, and mixtures or other combinations thereof. Certainmethods within the disclosure include methods wherein the fuel may be asubstantially gaseous fuel selected from the group consisting ofmethane, natural gas, liquefied natural gas, propane, carbon monoxide,hydrogen, steam-reformed natural gas, atomized oil or mixtures thereof,and the oxidant may be an oxygen stream comprising at least 90 molepercent oxygen.

The sources of oxidant and fuel may be one or more conduits, pipelines,storage facilities, cylinders, or, in embodiments where the oxidant isair, ambient air. Oxygen-enriched oxidants may be supplied from apipeline, cylinder, storage facility, cryogenic air separation unit,membrane permeation separator, or adsorption unit such as a vacuum swingadsorption unit.

“INCONEL®” as used herein means one or more of a family of austeniticnickel-chromium super alloys known under the trade designation INCONEL®,available from Special Metals Corporation, New Hartford, N.Y., U.S.A.The composition and some physical properties of austeniticnickel-chromium super alloy known under the trade designation INCONEL®alloy 600 are summarized in Tables 1 and 2 (from Publication NumberSMC-027 Copyright © Special Metals Corporation, 2008 (Sep. 8)).

TABLE 1 Chemical Composition, wt. %, of INCONEL ® Alloy 400 Nickel (plusCobalt) 72.0 min. Chromium 14.0-17.0 Carbon 0.15 max. Manganese 1.0 max.Iron 6.00-10.00 max. Sulfur 0.015 max. Silicon 0.50 max. Copper 0.50max.

TABLE 2 Physical Constants of INCONEL ® Alloy 600 Density, g/cm³ 8.47lb/in.³ 0.306 Melting range, ° F. 2470-2575 ° C. 1354-1413 Modulus ofElasticity, 10³ ksi (200 F) Young Modulus 30.5 Shear modulus 11.56Poisson's Ratio 0.319 Curie Temperature, ° F. −192 ° C. −124

Certain submerged combustion manufacturing systems may comprise asubmerged combustion melter (SCM) equipped with one or more submergedcombustion (SC) burners, the SCM having a length (L) and a width (W), acenterline (C), a midpoint (M), a sidewall structure having a north side(N) and a south side (S), the sidewall structure connecting a ceilingand a floor of the SCM, and one or more exhaust passages through theceiling or through the sidewall, or both, the exhaust passages having anaggregate hydraulic diameter; the one or more submerged combustionburners configured to discharge combustion products under a level ofmaterial being melted in the melter and create turbulent conditions insubstantially all of the material being melted as well as ejectedportions of melted material; and an exhaust structure fluidly connectingthe exhaust passage with an exhaust stack, the exhaust structurecomprising (or consisting essentially of, or consisting of): aliquid-cooled exhaust structure fluidly connected to the exhaustpassage, the liquid-cooled exhaust structure defining a liquid-cooledexhaust chamber having a first interior surface, the fluid-cooledexhaust chamber having a cross-sectional area greater than that of theexhaust stack but less than the melter, the exhaust passage andliquid-cooled exhaust structure configured to maintain temperature andpressure of the exhaust, and exhaust velocity through the exhaustpassage and the exhaust structure, at values sufficient to prevent theejected material portions of melted material from being propelled out ofthe exhaust structure as solidified material, and maintain any moltenmaterials contacting the first interior surface molten so that it flowsback down the first interior surface back into the melter.

Certain systems may comprise a gas-cooled exhaust structure fluidlyconnecting the liquid-cooled exhaust structure and the exhaust stack,the gas-cooled exhaust structure defining a gas-cooled exhaust chamberhaving a second interior surface, the gas-cooled exhaust structureconsisting of a metal layer forming the second interior surface, themetal layer having one or more gas-cooled external surfaces, thegas-cooled exhaust structure devoid of refractory or other lining.Certain systems may comprise the gas-cooled exhaust chamber having across-sectional area substantially equal to the cross-sectional area ofthe liquid-cooled exhaust chamber. Certain systems may comprise a feedinlet in a feed end of the wall structure, a molten product outlet in anexit end of the wall structure, wherein the exhaust passage through theceiling is positioned substantially centrally between the feed and exitends. Certain systems may comprise the exhaust passage and theliquid-cooled exhaust chamber having a cross-sectional area configuredto produce exhaust velocity of 25 ft./min. or less through the exhaustpassage and liquid-cooled exhaust chamber. Certain systems may comprisethe submerged combustion burners configured to discharge combustionproducts primarily non-laterally under the level of material beingmelted in the melter. Certain systems may comprise the submergedcombustion burners are configured to discharge combustion productsprimarily vertically under the level of material being melted in themelter. Certain systems may comprise the wall structure comprising afeed end wall, an exit end wall, and two sidewalls, with each sidewallconnected to both the feed end wall and the exit end wall. Certainsystems may comprise the liquid-cooled exhaust structure constructed ofmetal having service temperature higher than temperature of the exhaustmaterials. Certain systems may comprise the gas-cooled exhaust structureconstructed of metal having service temperature higher than temperatureof the exhaust materials. Certain systems may comprise the metal layerbeing one or more austenitic nickel-chromium super alloys, and theair-cooled surfaces are steel. Certain systems may comprise theliquid-cooled exhaust structure is configured for cooling using a liquidselected from the group consisting of water, organic liquids, inorganicliquids, and combinations thereof. Certain systems may comprise an airinspirator fluidly connecting the liquid-cooled exhaust barrier and theexhaust stack. Certain systems may comprise the air inspirator selectedfrom the group consisting of one or more adjustable panels, and one ormore adjustable hoods. Certain systems may comprise the exhauststructure having a cross-sectional shape selected from the groupconsisting of rectangular, round, oval, trapezoidal, triangular,U-shaped, quadrangular, hexagonal, octagonal, and parabolic.

Certain submerged combustion manufacturing methods may comprise meltingmaterials in a submerged combustion melter (SCM) equipped with one ormore submerged combustion (SC) burners, the SCM having a length (L) anda width (W), a centerline (C), a midpoint (M), a sidewall structurehaving a north side (N) and a south side (S), the sidewall structureconnecting a ceiling and a floor of the SCM, the melter comprising anexhaust passage through the ceiling, or the sidewall structure, or both;combusting a fuel in the one or more SC burners, the SC burnersdischarging combustion products under a level of the material beingmelted in the melter and creating turbulent conditions in substantiallyall of the material as well as ejected portions of melted material; andexhausting exhaust material from the melter through an exhaust structurefluidly connecting the exhaust passage with an exhaust stack, theexhaust structure comprising (or consisting essentially of, orconsisting of) a liquid-cooled exhaust structure, the liquid-cooledexhaust structure defining a liquid-cooled exhaust chamber having afirst interior surface, the liquid-cooled exhaust structure configuredto prevent the ejected material portions of melted material from beingpropelled out of the exhaust structure as solidified material, andmaintain any molten materials contacting the first interior surfacemolten so that it flows back down the first interior surface back intothe melter.

Certain methods may comprise exhausting the exhaust material from theliquid-cooled exhaust structure to a gas-cooled exhaust structurefluidly connecting the liquid-cooled exhaust structure and the exhauststack, the gas-cooled exhaust structure defining a gas-cooled exhaustchamber having a second interior surface, the gas-cooled exhauststructure consisting of a metal layer forming the second interiorsurface, the metal layer having one or more gas-cooled externalsurfaces, the gas-cooled exhaust structure devoid of refractory or otherlining. Certain methods may comprise wherein the melting, combusting,and exhausting are performed, and the exhaust passage and theliquid-cooled exhaust chamber configured to produce exhaust velocity of25 ft./min. or less through the exhaust passage and liquid-cooledexhaust chamber. Certain methods may comprise wherein the exhaustpassage is substantially centrally located between a feed end and anexit end of the melter, and the exhausting of the exhaust materialthrough the exhaust structure comprises exhausting the exhaust materialsubstantially centrally between the feed end and the exit end of themelter. Certain methods may comprise inspiring air into the exhaustmaterial through an air inspirator fluidly connecting the liquid-cooledexhaust structure and the exhaust stack. Certain methods may compriseadjusting the air inspirator to allow more or less air to enter theexhaust stack. Certain methods may comprise feeding small (less than 1mm APS) particle size batch material to the SCM into at least one feedinlet port. Certain methods may comprise feeding large particle sizefeedstock (at least 10 cm APS) into the SCM through one or moreauxiliary inlet ports.

Referring now to the drawing figures, FIG. 1 is a schematic perspectiveview, partially in phantom, of a first embodiment 100 of a submergedcombustion manufacturing system in accordance with the presentdisclosure. Embodiment 100 includes nine ports for SC burners 4A, 4B,4C, 6A, 6B, 6C, 10A, 10B, and 10C arranged in a 3×3 matrix of rows andcolumns, as illustrated schematically in the plan view of one melterfloor plan in FIG. 8. The SCM includes a sidewall structure including afeed end wall 8A, a product exit end wall 8B, a north sidewall 8C, and asouth sidewall 8D, SCM floor 12 supported by a support 2, and a roof orceiling 14. Embodiment 100 includes a circular exhaust passage 15 ofdiameter d through ceiling 14 fluidly connected to a liquid-cooledexhaust structure 40 having a height H1, which may in turn be fluidlyconnected to a gas-cooled exhaust structure 30 having a height H7. Incertain embodiments gas-cooled exhaust structure is deleted, where H7=0.Gas-cooled exhaust structure 30 is fluidly connected to a metaltransition piece 36, which in turn connects to a conventional metalexhaust stack 16 that leads exhaust gases to a baghouse or otherenvironmental compliance unit or units. The liquid-cooled exhaustsection 40 may comprise an internal panel 42 and an external panel 44,with any of a variety of liquid channels formed there between for flowof a cooling liquid, such as water or other heat transfer liquid, whichmay enter through a conduit 48 and exit through another conduit 50. Theinternal surface of internal panel 42 defines a liquid-cooled exhaustchamber 33. Similarly, gas-cooled exhaust structure, if present, wouldbe formed from an internal metal panel 34 made of a metal such as one ofthe austenitic nickel-chromium super alloys known under the tradedesignation INCONEL®, with steel gas-cooling features 38, such as finsor compartments for flowing a gas such as air or other gas therethrough,such as nitrogen, a halogenated gas such as tri-chloroethane, and thelike. Internal metal panel 34 defines a gas-cooled exhaust chamber 23. Adashed vertical line schematically illustrates a longitudinal axis A ofthe exhaust structure. A centerline of the SCM is designated by dashedline C, and a midpoint line is designated as M. G designates ageographic center point of the melter, the intersection of imaginarylines C and M. Features C and M are also schematically illustrated inFIG. 8. A particulate feedstock inlet 22A is indicated in ceiling 14,and an alternate feedstock location is indicated at 22B in feed end wall8C, 22B preferably located in a splash region of the SCM, as more fullydiscussed in relation to embodiment 300 (FIGS. 6 and 7). Particulatefeedstock inlet 22A or 22B (there may be more than one) is/are fed by aparticulate feeder (not illustrated), which may include an auger orscrew feeder (not illustrated), as well as a device to maintain thefeedstock inlet open, such as a pipe-in-pipe knife arranged insidefeeder tube 22B operated by an actuator with a timer for example (theknife, actuator, and timer are not illustrated for clarity). Other feedinlets, not illustrated but for example for scrap, as described inassignee's U.S. Pat. No. 8,650,914 may be present in feed end wall 8C incertain embodiments. While not important to the various SCM and methodembodiments described herein, the SCM is typically fluidly connected to(but not necessarily structurally connected to) a melter exit structurethrough a product exit spout 18.

Important to certain methods of the present disclosure are thedefinitions exemplified schematically in FIG. 8: R1, R2, and R3designate the first row, second row, and third row of SC burners, wherethe first row R1 is closest to the feed end of the SCM, and the thirdrow R3 is closest to the melt exit end. There may be more or less thanthree rows of SC burners. Further defined in FIG. 8 are the length (L)of the SCM, the width (W), the midpoint (M), the centerline (C), and thenorth (N) and south (S) sides of the SCM, the SCM having a feed end (F)and exit end (E).

FIG. 2 is a schematic perspective view, partially in phantom, of asecond embodiment 200 of a submerged combustion manufacturing system inaccordance with the present disclosure. System 200 is mounted on a plantfloor 202 or other support. Embodiment 200 includes an SCM 210 supportedon support 202, the SCM having an SCM floor 212, roof or ceiling 214,and a trapezoidal exhaust passage formed in ceiling 214 by sides 218,220, 222, and 224. Submerged combustion burners are not viewable in thisembodiment, but are inserted through the floor 212 as in embodiment 100.Melter 210 includes inlet and outlet end walls 208A and 208B,respectively, sidewalls 209A (not visible in FIG. 2) and 209B, and aroof 214. Melter 210 has a pair of angled sidewalls 244A, 244B (only244B being visible), as well as downwardly sloping front and back endpanels 242A and 242B. Melter 210 actually has a double trapezoidalshape, with the inlet end having the longer side 215 of a firsttrapezoid mating with the longer side of a second trapezoid having asecond end 217, shown by the dashed line in FIG. 2. Melter 210 includesa feed end wall feed inlet 239A, an alternate or additional feed inletin ceiling 239B, and a molten glass outlet near a bottom of end wall208B that is not viewable in FIG. 2.

An exhaust structure in embodiment 200 is defined by a water-cooledexhaust structure 230 and an air-cooled exhaust structure 240.Water-cooled exhaust structure 230 has a double-trapezoidcross-sectional shape similar to the exhaust opening defined by 218,220, 222, and 224, although this is not necessary, as other rectilineartwo-dimensional shapes (for example triangular, square, rectangle, andthe like) or curvilinear two-dimensional shapes (circular, elliptical,arcuate, and the like), or combinations thereof (for example, ahemisphere intersecting a rectangle) may be envisioned. Water-cooledexhaust structure 230 includes a water inlet conduit 250 and a waterexit conduit 260 (there may be more than one of each), and is adouble-walled structure such as illustrated schematically in thecross-section of FIG. 5. Referring to FIG. 5, front and rear externalpanels 280A and 280B form with external side panels 282A and 282B anouter trapezoid, with an inner trapezoid formed by panels 281A, 281B,283A, and 283B. The panels may be welded, brazed, or otherwise heldtogether, such as by rivets, bolts, or clamps. Partitions 284 may besimilarly attached, and form with the panels a set of water flowchannels 286.

Referring again to FIG. 2, as well as FIG. 4, an air-cooled exhauststructure 240 is defined by a front cooling panel 240A, back wallcooling panel 240B (not illustrated) and sidewall cooling panels 228Aand 228B (side wall cooling panel 228A not viewable in FIG. 4). An airinspirator is provided comprising in this embodiment two adjustable sidepanels 232A (not visible in FIG. 2) and 232B, an adjustable front panel234A, and an adjustable back panel 234B (not visible in FIG. 2).Adjustable panels 232A, 232B, 234A, and 234B may be adjusted usinghinges, hydraulic or pneumatic pistons, motors, or any other mechanism.A metal transition piece or hood 236 is provided, fluidly connectinginspirator panels 232A, 232B, 234A, and 234B to a connector 216 thatconnects to a conventional metal stack (not illustrated). In analternative embodiment, not illustrated, inspirator panels 232A, 232B,234A, and 234B may be replaced by hood 236 that may be movable up anddown to adjust air inspiration into hood 236. Hood 236 may be configuredto move up and down in a variety of ways, for example by adding guides,rails, wheels, jack screws, one or more motors, and the like to thehood. Such an arrangement is illustrated in assignee's '740 patent,mentioned in the Background. Hood 236 may be moved up or down usingguide wires, for example, using lifting eyes.

FIG. 3 is a more detailed schematic perspective view of a portion of theair-cooled exhaust structure of the melter and system embodiment of FIG.2, illustrating in more detail cooling panels 228B and 240B, each havingthree vertical flow-though sections separated by partitions 228C, 228D,240C, and 240D. Cooling panels 228A, 228B, 240A, and 240B have airinlets generally noted at 246 at the bottom of the vertical flow-throughsections, and air outlets generally noted at 248 at the top of thevertical flow-through sections. Also viewable in FIG. 3 is a trapezoidalmetal panel 226 (constructed of metal such as that known under the tradedesignation INCONEL® in embodiment 200). Notably, air-cooled exhaustsection 240 of embodiment 200 has no (is devoid of) refractory or otherlining other than the metal panel 226 constructed of metal such as thatknown under the trade designation INCONEL®. It was found that arefractory lining would in some instances actually melt when contactedby molten glass or other molten material ejected from the violent,extremely turbulent conditions of an aggressively fired SCM, solidify,and then fall back down into the melter, adversely affecting compositionof the molten material and in some instances depositing stones into theSCM melt product that would carryover into glass fiber formingoperations, causing shutdown of such operations.

FIG. 6 is a schematic end elevation view, partially in cross-section, ofa third embodiment 300 of a submerged combustion manufacturing system inaccordance with the present disclosure having two sidewall exhaustdischarge ports 315A and 315B positioned at a height H2, and FIG. 7 is amore detailed schematic side elevation view, partially in cross-section,of embodiment 300. Embodiment 300 is supported on a support 302 (plantfloor or other) and includes 9 SC burners in a 3×3 pattern, with SCburners 304A, 304B, and 304C being illustrated in FIG. 6, while FIG. 7illustrates SC burners 304C, 306C, and 310C (burners 304A, 304B, 306A,306B, 310A, and 310B are not visible in the side elevation of FIG. 7).Embodiment 300 includes feed end wall 308A and product end wall 308Bincluding a product spout 318, and SCM floor 312, ceiling 314, analternate ceiling feed port 322A, and a feed end wall feed port 322Bfeeding a splash region having a height H4. The SCM has a headspacehaving a height H6, and a turbulent molten material region having aheight H5. The SCM has an internal height H3, where H3=H4+H5+H6. The SCMincludes liquid-cooled exhaust structures 326A (north side) and 326B(south side) each having a height H1 and each comprising a heat andcorrosion-resistant metal such as that known under the trade designationINCONEL®, as well as an air-cooled exhaust structure 340 having a frontair-cooled panel 340A, also comprising a heat and corrosion-resistantmetal such as that known under the trade designation INCONEL®, and, incertain embodiments, devoid of any refractory lining. Adjustable sideair inspirators 332A, 332B, as well as as adjustable front and back airinspirators 334A and 334B are provided (the latter not viewable in FIG.7). A metal transition piece or hood 336 fluidly connects air-cooledexhaust structure 340 a conventional metal stack 316 that routes cooledexhaust to environmental compliance units. The SCM of embodiment 300further includes a refractory lining 346, which may comprise one or morefluid-cooled panels (“fluid-cooled” is a defined term herein).

Important features of embodiment 300 include the provision of an angle“α” of the initial portions of the liquid-cooled exhaust structures 326Aand 326B that fluidly connect these structures with their respectiveexhaust openings 315A and 315B. This “exhaust angle” a is configured toassist the liquid-cooled exhaust structure in preventing the ejectedmaterial portions of melted material from being propelled out of theexhaust structure as solidified material, and maintain any moltenmaterials contacting the first interior surface molten so that it flowsback down the first interior surface back into the melter, and may rangefrom about 20 degrees to about 80 degrees (the angle may be the same ordifferent for 315A and 315B). All individual values and subranges ofexhaust angle from about 20 degrees up to about 80 degrees are includedherein and disclosed herein; for example, the exhaust angle may rangefrom a lower limit of 17, 20, 25.5, 26, 27, 34.8, 44, 53.5, 62.9, 65, or70 degrees to an upper limit of 85, 81.5, 72.5, 63.5, 54, 45, 40, 35,32, 30, 27, or 25 degrees. For example, from about 17 to about 77degrees, or from about 39 to about 73 degrees, or from about 49.5 toabout 65 degrees.

Also illustrated schematically in FIGS. 6 and 7 are positions of SCburners 304A, 304B, 304C, 306C, and 310C, with the understanding burners306A, 306B, 310A, and 310B are not illustrated. The SC burners createturbulent molten material or melt 350 in a turbulent melt region havinga height H5 (with curved arrows 356 indicating approximate flow patternfor the turbulent melt), a splash region having a height H4, and ejectedportions of molten material 352 in the SCM headspace having a height H6.The ejected portions of molten material 352 (gobs, blobs or splashes)are caused by the nature of SC burners, which cause large balloons 354of combustion gases to rise in the molten material, which then burst andpropel the blobs 352 with sufficient force to break free and in somecases obtain free flight. Blobs 352 and may collide with each other orwith the refractory inside the SCM, or they may simply fall back intothe splash region and fall further into the molten melt. For this andother reasons, another important feature is the height H2 of the exhaustpassages 315A and 315B, which must be of sufficient height to be abovethe height H4 of the splash region. H2 must be greater than the heightof the molten material H5 plus height of the splash region H4,preferably 5 percent more, or 6, 7, 8, 9, 10, 11.5, 12, 13.6, 15, 20, or30 percent more than H5+H4.

Certain embodiments make take advantage of the teachings of Applicant'sco-pending U.S. application Ser. No. 15/293,463, filed Oct. 14, 2016,which describes a relationship between the height of particulatefeedstock inlet ports measured from the SCM floor and the height of theSCM ceiling as measured from the SCM floor, and the maximum height ofthe splash region and the minimum height of the splash region. Incertain embodiments the ratio of the height of particulate feedstockinlet ports/the height of the SCM ceiling may be an important parameter,and may range from about 0.33 to about 0.67. All ranges, sub-ranges, andpoint values from about 0.33 to about 0.67 are explicitly disclosedherein.

FIGS. 9 and 10 are logic diagrams illustrating two methods of thepresent disclosure. FIG. 9 illustrates a method 900 of melting materialsin a submerged combustion melter (SCM) equipped with one or moresubmerged combustion (SC) burners, the SCM having a length (L) and awidth (W), a centerline (C), a midpoint (M), a sidewall structure havinga north side (N) and a south side (S), the sidewall structure connectinga ceiling and a floor of the SCM, the melter comprising one or moreexhaust passage through the ceiling (Box 902). Method embodiment 900further comprises combusting a fuel in the one or more SC burners, theSC burners discharging combustion products under a level of the materialbeing melted in the melter and creating turbulent conditions insubstantially all of the material as well as ejected portions of meltedmaterial (Box 904). Method embodiment 900 further comprises exhaustingexhaust material from the melter through an exhaust structure fluidlyconnecting the exhaust passage with an exhaust stack, the exhauststructure comprising (or consisting essentially of, or consisting of) aliquid-cooled exhaust structure, the liquid-cooled exhaust structuredefining a liquid-cooled exhaust chamber having a first interiorsurface, the liquid-cooled exhaust structure configured to prevent theejected material portions of melted material from being propelled out ofthe exhaust structure as solidified material, and maintain any moltenmaterials contacting the first interior surface molten so that it flowsback down the first interior surface back into the melter (Box 906).

FIG. 10 illustrates a method 1000 of melting materials in a submergedcombustion melter (SCM) equipped with one or more submerged combustion(SC) burners, the SCM having a length (L) and a width (ON), a centerline(C), a midpoint (M), a sidewall structure having a north side (N) and asouth side (S), the sidewall structure connecting a ceiling and a floorof the SCM, the melter comprising one or more exhaust passage throughthe ceiling (Box 1002). Method embodiment 1000 further comprisescombusting a fuel in the one or more SC burners, the SC burnersdischarging combustion products under a level of the material beingmelted in the melter and creating turbulent conditions in substantiallyall of the material as well as ejected portions of melted material (Box1004). Method embodiment 1000 further comprises exhausting exhaustmaterial from the melter through an exhaust structure fluidly connectingthe exhaust passage with an exhaust stack, the exhaust structurecomprising (or consisting essentially of, or consisting of) aliquid-cooled exhaust structure, the liquid-cooled exhaust structuredefining a liquid-cooled exhaust chamber having a first interiorsurface, the liquid-cooled exhaust structure configured to prevent theejected material portions of melted material from being propelled out ofthe exhaust structure as solidified material, and maintain any moltenmaterials contacting the first interior surface molten so that it flowsback down the first interior surface back into the melter (Box 1006).

In operation, flow of feedstock (including particulate feedstock) intothe SCM may be continuous, semi-continuous, semi-batch, or batch. Forexample, in certain embodiments feedstock could flow into a feedstockheat exchange substructure until the feedstock heat exchangesubstructure is partially full or completely full of feedstock, then thepre-heated feedstock may be dumped into the SCM. One way ofaccomplishing that may be by use of a grating at the bottom of afeedstock heat exchange substructure having openings slightly smallerthan the feedstock particle size. Such an arrangement is disclosed inassignee's copending U.S. patent application Ser. No. 14/844,198, filedSep. 3, 2015, incorporated by reference herein.

The initial raw material feedstock may include any material suitable forforming molten inorganic materials. In certain embodiments where thefeedstock is pre-heated by melter exhaust, some non-particulatefeedstock may have a weight average particle size such that most if notall of the feedstock is not fluidized when traversing through the heatexchange structure or exhaust conduit serving as the heat exchangestructure. Such materials may include glass precursors or othernon-metallic inorganic materials, such as, for example, limestone, glasscullet, feldspar, basalt or other rock wool or mineral wool formingmaterial, scrap glass (including glass fiber in various forms), scraprock or mineral wool, and mixtures thereof. Typical examples of basaltthat are compositionally stable and available in large quantities arereported in U.S. Patent Publication 20120104306, namely an ore having alarger amount of SiO₂ (A, for high-temperature applications) and an orehaving a smaller amount of SiO₂ (B, for intermediate-temperatureapplications), both of which have approximately the same amount ofAl₂O₃. Although ore A can be spun into fiber, the resultant basalt fiberhas heat-resistance problem at temperature ranges exceeding 750° C. OreB, on the other hand, is associated with higher energy cost for massproduction of fiber. The basalt rock material feedstock for use on thesystems and methods of the present disclosure may be selected from: (1)high-temperature ore (A) having substantially the same amount of Al₂O₃and a larger amount of SiO₂; (2) intermediate-temperature ore (B) havingsubstantially the same amount of Al₂O₃ and a smaller amount of SiO₂: and(3) a mixture of the high-temperature basalt rock ore (A) and theintermediate-temperature basalt rock ore (B).

Basalt rock (basalt ore) is an igneous rock. According to U.S. PatentPublication 20120104306, major examples of the constituent mineralinclude: (1) plagioclase: Na(AlSi₃O₈)—Ca(Al₂SiO₈); (2) pyroxene: (Ca,Mg, Fe²⁺, Fe³⁺, Al, Ti)₂[(Si, AI)₂O₆]; and (3) olivine: (Fe, Mg)₂SiO₄.Ukrainian products are inexpensive and good-quality.

Tables 3 and 4 (from U.S. Patent Publication 20120104306) show examplesof element ratios (wt. %) and the oxide-equivalent composition ratios(wt. %) determined by ICP analysis (using an inductively-coupled plasmaspectrometer ICPV-8100 by Shimadzu Corporation) performed on ahigh-temperature basalt ore (for high-temperature applications), anintermediate-temperature basalt ore (for intermediate-temperatureapplications), and a glass consisting of 85% high-temperature ore and15% intermediate-temperature ore.

TABLE 3 Ore Ore (for Ore (for high-temp.) 85 wt % (for high-temp.)intermediate-temp.) Ore (for intermediate-temp.) (wt %) (wt %) 15 wt %(wt %) Si 23.5~28.8 23.5~28.5 25.0~28.8 Al 8.7~9.3 8.7~9.3 9.0~9.5 Fe6.0~6.6 6.0~7.1 5.7~6.7 Ca 4.0~4.5 5.6~6.1 4.2~4.7 Na 2.1~2.3 1.8~2.02.0~2.3 K 1.4~1.8 1.2~1.5 1.4~1.9 Mg 0.1~1.6 1.4~3.0 1.5~1.7 Ti 0.4~0.60.5~0.7 04~0.6 Mn 0.1~0.2 0.1~0.2 0.1~0.2 P 0.05~0.10 0.05~0.090.07~0.10 B 0.02~0.08 0.01~0.06 0.03~0.10 Ba 0.03~0.05 0.03~0.05 0.09 Sr0.02~0.04 0.02~0.04 0.02~0.05 Zr 0.01~0.04 0.01~0.04 0.01~0.03 Cr0.01~0.03 0.01~0.03 0.01~0.03 S 0.01~0.03 0.01~0.03 0.01~0.03

TABLE 4 Ore (for high-temp.) Ore Ore (for 85 wt % Ore (for (forhigh-temp.) intermediate-temp.) intermediate-temp.) (wt %) (wt %) 15 wt% (wt %) SO₂ 57.1~61.2 54.0~58.2 57.7~60.6 Al₂O₃ 16.1~19.2 14.9~18.116.5~18.9 FeO + Fe₂O₃ 8.0~9.7 8.1~9.6 7.7~9.6 CaO 5.5~6.8 7.5~8.85.8~7.0 Na₂O 2.8~3.3 2.2~2.9 2.6~3.2 K₂O 1.8~2.1 1.4~1.8 1.8~2.2 MgO0.20~2.5  1.4~4.8 0.2~2.8 TiO₂ 0.7~1.0 0.8~1.1 0.1~0.3 MnO 0.1~0.30.1~0.3 0.1~0.3 P₂O₅ 0.1~0.3 0.1~0.3 0.1~0.3 B₂O₃ 0.1~0.3 0.04~0.200.04~0.30 BaO 0.03~0.07 0.02~0.06 0.03~0.12 SrO 0.02~0.06 0.02~0.070.01~0.06 ZrO₂ 0.02~0.05 0.02~0.05 0.01~0.30 Cr₂O₃ 0.01~0.05 0.01~0.050.01~0.04 SO 0.01~0.03 0.01~0.03 0.01~0.03

In embodiments wherein glass batch is used as sole or as a supplementalfeedstock, one glass composition for producing glass fibers is“E-glass,” which typically includes 52-56% SiO₂, 12-16% Al₂O₃, 0-0.8%Fe₂O₃, 16-25% CaO, 0-6% MgO, 0-10% B₂O₃, 0-2% Na₂O+K₂O, 0-1.5% TiO₂ and0-1% F₂. Other glass batch compositions may be used, such as thosedescribed in assignee's published U.S. application 20080276652.

As noted herein, submerged combustion burners and burner panels mayproduce violent or aggressive turbulence of the molten inorganicmaterial in the SCM and may result in sloshing or splashing of moltenmaterial, pulsing of combustion burners, popping of large bubbles abovesubmerged burners, ejection of molten material from the melt against thewalls and ceiling of melter, and the like. Frequently, one or more ofthese phenomena may result in undesirably short life of temperaturesensors and other components used to monitor a submerged combustionmelter's operation, making monitoring difficult, and use of signals fromthese sensors for melter control all but impossible for more than alimited time period. Processes and systems of the present disclosure mayinclude indirect measurement of melt temperature in the melter itself,as disclosed in assignee's U.S. Pat. No. 9,096,453, using one or morethermocouples for monitoring and/or control of the melter, for exampleusing a controller. A signal may be transmitted by wire or wirelesslyfrom a thermocouple to a controller, which may control the melter byadjusting any number of parameters, for example feed rate of a feedstockfeeder may be adjusted through a signal, and one or more of fuel and/oroxidant conduits may be adjusted via a signal, it being understood thatsuitable transmitters and actuators, such as valves and the like, arenot illustrated for clarity.

Melter apparatus in accordance with the present disclosure may alsocomprise one or more wall-mounted submerged combustion burners, and/orone or more roof-mounted non-submerged burners (not illustrated).Roof-mounted burners may be useful to pre-heat the melting zone of theSCM, and serve as ignition sources for one or more submerged combustionburners and/or burner panels. Roof-mounted burners may be oxy-fuelburners, but as they are only used in certain situations, are morelikely to be air/fuel burners. Most often they would be shut-off afterpre-heating the melter and/or after starting one or more submergedcombustion burners. In certain embodiments, one or more roof-mountedburners could be used supplementally with a baffle (for example, whenthe baffle requires service) to form a temporary curtain to preventparticulate carryover. In certain embodiments, all submerged combustionburners and burner panels may be oxy/fuel burners or oxy-fuel burnerpanels (where “oxy” means oxygen, or oxygen-enriched air, as describedearlier), but this is not necessarily so in all embodiments; some or allof the submerged combustion burners or burner panels may be air/fuelburners. Furthermore, heating may be supplemented by electrical (Joule)heating in certain embodiments, in certain melter zones.

Certain SCM embodiments may comprise burner panels as described inassignee's U.S. patent Ser. No. 14/838,148, filed Aug. 27, 2015,comprising a burner panel body and one or more sets of concentricconduits for flow of oxidant and fuel. Certain burner panels disclosedtherein include those wherein the outer conduit of at least some of thesets of concentric conduits are oxidant conduits, and the at least oneinner conduit is one or more fuel conduits. Certain burner panelembodiments may comprise non-fluid cooled or fluid-cooled protectivemembers comprising one or more noble metals. Certain burner panelembodiments may comprise non-fluid cooled or fluid-cooled protectivemembers consisting essentially of one or more noble metals. Certainburner panel embodiments may comprise non-fluid cooled or fluid-cooledprotective members consisting of one or more noble metals. Certainburner panel embodiments may comprise those wherein the lowerfluid-cooled portion and the upper non-fluid cooled portion arepositioned in layers, with the lower fluid-cooled portion supporting thesets of conduits and the associated protective members. Certain burnerpanel embodiments may comprise those wherein the non-fluid cooledprotective member is a shaped annular disk having a through passage, thethrough passage of the shaped annular disk having an internal diametersubstantially equal to but not larger than an internal diameter of theouter conduit. Certain burner panel embodiments may comprise thosewherein an internal surface of the through passage of the shaped annulardisk and a portion of a top surface of the shaped annular disk are notsubmerged by the fluid-cooled or non-fluid-cooled portions of the panelbody. Certain combustion burner panels may comprise a panel body havinga first major surface defined by a lower fluid-cooled portion of thepanel body, and a second major surface defined by an upper non-fluidcooled portion of the panel body, the panel body having at least onethrough passage extending from the first to the second major surface,the through passage diameter being greater in the lower fluid-cooledportion than in the upper non-fluid cooled portion, the panel bodysupporting at least one set of substantially concentric at least oneinner conduit and an outer conduit, each conduit comprising proximal anddistal ends, the at least one inner conduit forming a primary passageand the outer conduit forming a secondary passage between the outerconduit and the at least one inner conduit; and a fluid-cooledprotective member associated with each set and having connections forcoolant fluid supply and return, each fluid-cooled protective memberpositioned adjacent at least a portion of the circumference of the outerconduit between the proximal and distal ends thereof at approximately aposition of the fluid-cooled portion of the panel body. Certain burnerpanel embodiments may comprise those wherein each fluid-cooledprotective member is a fluid-cooled collar having an internal diameterabout the same as an external diameter of the outer conduit, thefluid-cooled collar having an external diameter larger than the internaldiameter. Certain burner panel embodiments may comprise a mountingsleeve. In certain burner panel embodiments the mounting sleeve having adiameter at least sufficient to accommodate the external diameter of thefluid-cooled collar. In certain embodiments, the burner panel mayinclude only one or more fuel conduits, or only one or more oxidantconduits. These embodiments may be paired with other panels supplyingfuel or oxidant (as the case might be), the pair resulting in combustionof the fuel from one panel with the oxidant from the other panel. Incertain embodiments the burner panel may comprise a pre-disposed layeror layers of glass, ceramic, refractory, and/or refractory metal orother protective material as a protective skull over the non-fluidcooled body portion or layer. The layer or layers of protective materialmay or may not be the same as the material to be melted in the SCM.

There are innumerable options, variations within options, andsub-variations of options for the SCM operator to select from whenoperating an SCM and profiling the SC burners. After all, the SCM isessentially a continuous or semi-batch chemical reactor withsimultaneous heat and mass transfer. For example, to name just a few, anoperator may choose (option 1) to operate all SC burners equally, thatis, using the same fuel and oxidant, and of the total combustion flowrate (TCFR) from the SC burners, each SC burner is operated to producethe same fraction of the TCFR. Another option (option 2) would be tooperate as option 1, but with different oxidant in one or more burners.Option 3 may be to operate with same oxidant in all burners, but withdifferent fuel in one or more SC burners. As one can readily see, thenumber of options is quite large, and selecting the operation of the SCburners in such a chemical reactor with simultaneous heat and masstransfer can be an overwhelming task. Even if the “same” fuel and “same”oxidant are used for each SC burner (an ideal assumption that is nevertrue in practice, since fuel and oxidant compositions change with time),the variations are endless, and can be an overwhelming task to sortthrough. The task of operating an SCM is even more daunting whenparticulate feed materials are fed to the SCM from above the turbulent,violent melt. In certain embodiments herein, SC burners that aredirectly underneath an exhaust opening in an SCM having ceiling exhaustopenings may be reduced in firing rate, or completely shut off, in orderto minimize ejection of molten material form the melt. Such operationshould also reduce the tendency to eject solidified pellets out of themelter stack when aggressively firing the SC burners. The reduction infiring rate of SC burners directly under the exhaust openings may be 5percent, or 6, 7, 8, 8.5, 9, 9.3, 10, 11, 15, 25, 35, 55, or 75 percent,or 100 percent if shut off. For example, in embodiment 200 (FIG. 2),firing rate of SC burners 6A and 6B may be reduced or shut off. Thisreduction of firing rate of SC burners may also be practiced for SCburners in close proximity of exhaust passages in the sidewalls. Forexample, in embodiment 300, it may be desirable to reduce firing rate ofSC burners 306A and 306C in relation to the other SC burners.

Suitable materials for glass-contact refractory, which may be present inSCMs, burners, and burner panels useful herein, include AZS(alumina-zirconia-silica), α/β alumina, zirconium oxide, chromium oxide,chrome corundum, so-called “dense chrome”, and the like. One “densechrome” material is available from Saint Gobain under the trade nameSEFPRO, such as C1215 and C1221. Other useable “dense chrome” materialsare available from the North American Refractories Co., Cleveland, Ohio(U.S.A.) under the trade designations SERV 50 and SERV 95. Othersuitable materials for components that require resistance to hightemperatures are fused zirconia (ZrO₂), fused cast AZS(alumina-zirconia-silica), rebonded AZS, or fused cast alumina (Al₂O₃).The choice of a particular material may be dictated by the geometry ofthe apparatus, the type of material being produced, operatingtemperature, burner body panel geometry, and type of glass or otherproduct being produced.

The term “fluid-cooled” means use of any coolant fluid (heat transferfluid) to transfer heat away from the equipment in question, other thanambient air that resides naturally on the outside of the equipment. Forexample, portions of or the entire panels of sidewall structure, floor,and ceiling of the SCM, liquid-cooled and gas-cooled exhaust structures,portions or all of heat transfer substructures used to preheat feedstock(for example nearest the melter), portions of feedstock supply conduits,and portions of SC burners, and the like may require fluid cooling. Heattransfer fluids may be any gaseous, liquid, slurry, or some combinationof gaseous, liquid, and slurry compositions that functions or is capableof being modified to function as a heat transfer fluid. Gaseous heattransfer fluids may be selected from air, including ambient air andtreated air (for example, air treated to remove moisture), inorganicgases, such as nitrogen, argon, and helium, organic gases such asfluoro-, chloro- and chlorofluorocarbons, including perfluorinatedversions, such as tetrafluoromethane, and hexafluoroethane, andtetrafluoroethylene, and the like, and mixtures of inert gases withsmall portions of non-inert gases, such as hydrogen. Heat transferliquids and slurries may be selected from liquids and slurries that maybe organic, inorganic, or some combination thereof, for example, water,salt solutions, glycol solutions, oils and the like. Heat transferliquids and slurries may comprise small amounts of various gases such asoxygen and nitrogen present in air bubbles. Heat transfer gases maycomprise small amounts of various liquids such as condensed waterdroplets. Other possible heat transfer fluids include steam (if coolerthan the expected glass melt temperature), carbon dioxide, or mixturesthereof with nitrogen. Heat transfer fluids may be compositionscomprising both gas and liquid phases, such as the higherchlorofluorocarbons. Certain SCMs and method embodiments of thisdisclosure may include fluid-cooled panels such as disclosed inassignee's U.S. Pat. No. 8,769,992.

Certain systems and processes of the present disclosure may utilizemeasurement and control schemes such as described in Applicant's U.S.Pat. No. 9,096,453, and/or feed batch densification systems and methodsas described in Applicant's U.S. Pat. No. 9,643,869. Certain SCMs andprocesses of the present disclosure may utilize devices for delivery oftreating compositions such as disclosed in Applicant's U.S. Pat. No.8,973,405.

Certain SCM and method embodiments of this disclosure may be controlledby one or more controllers. For example, combustion (flame) temperaturemay be controlled by monitoring one or more parameters selected fromvelocity of the fuel, velocity of the primary oxidant, mass and/orvolume flow rate of the fuel, mass and/or volume flow rate of theprimary oxidant, energy content of the fuel, temperature of the fuel asit enters burners or burner panels, temperature of the primary oxidantas it enters burners or burner panels, temperature of the effluent(exhaust) at melter exhaust exit, pressure of the primary oxidantentering burners or burner panels, humidity of the oxidant, burner orburner panel geometry, combustion ratio, and combinations thereof.Certain SCMs and processes of this disclosure may also measure and/ormonitor feed rate of batch or other feedstock materials, such as rockwool or mineral wool feedstock, glass batch, cullet, mat or wound rovingand treatment compositions, mass of feed, and use these measurements forcontrol purposes. Flow diverter positions may be adjusted or controlledto increase heat transfer in heat transfer substructures and exhaustconduits.

Various conduits, such as feedstock supply conduits, exhaust conduits,heat-transfer fluid supply and return conduits, oxidant and fuelconduits of burners or burner panels of the present disclosure may becomprised of metal, ceramic, ceramic-lined metal, or combinationthereof. Suitable metals include carbon steels, stainless steels, forexample, but not limited to, 306 and 316 steel, as well as titaniumalloys, aluminum alloys, and the like. High-strength materials likeC-110 and C-125 metallurgies that are NACE qualified may be employed forburner body components. (As used herein, “NACE” refers to the corrosionprevention organization operating under the name NACE International,Houston, Tex.) Use of high strength steel and other high strengthmaterials may significantly reduce the conduit wall thickness required,reducing weight of the conduits and/or space required for conduits. Incertain locations, precious metals and/or noble metals (or alloys) maybe used for portions or all of these conduits. Noble metals and/or otherexotic corrosion and/or fatigue-resistant materials such as platinum(Pt), ruthenium (Ru), rhodium (Rh), palladium (Pd), silver (Ag), osmium(Os), iridium (Ir), and gold (Au); alloys of two or more noble metals;and alloys of one or more noble metals with a base metal may beemployed. In certain embodiments a protective layer or layers orcomponents may comprise an 80 wt. percent platinum/20 wt. percentrhodium alloy attached to a base metal using brazing, welding orsoldering of certain regions, as further explained in assignee's U.S.patent application Ser. No. 14/778,206, filed Sep. 18, 2015.

The choice of a particular material is dictated among other parametersby the chemistry, pressure, and temperature of fuel and oxidant used andtype of melt to be produced with certain feedstocks. The skilledartisan, having knowledge of the particular application, pressures,temperatures, and available materials, will be able design the most costeffective, safe, and operable heat transfer substructures, feedstock andexhaust conduits, burners, burner panels, and melters for eachparticular application without undue experimentation.

The total quantities of fuel and oxidant used by SC burners or SC burnerpanels may be such that the flow of oxygen may range from about 0.9 toabout 1.2 of the theoretical stoichiometric flow of oxygen necessary toobtain the complete combustion of the fuel flow. Another expression ofthis statement is that the combustion ratio may range from about 0.9 toabout 1.2. The amount of heat needed to be produced by combustion offuel in the melter (and/or Joule heating) will depend upon theefficiency of any preheating of the feedstock in a feedstock heatexchange substructure, if present. The larger the amount of heattransferred to the feedstock, the lower the heat energy required in themelter from the fuel and/or Joule elements. When operating “lean”, thecombustion ratio is above about 1.0, or above about 1.5, or above about2.0, or above about 2.5. When operating “rich”, the combustion ratio isbelow about 1.0, or below about 0.9, or below about 0.8, or below about0.7, or below about 0.6, or below about 0.5, or below about 0.2.

In SCMs, the velocity of the fuel in the various SC burners and/or SCburner panels depends largely on the burner/burner panel geometry used,but generally is at least about 15 meters/second (m/s). The upper limitof fuel velocity depends primarily on the desired penetration of flameand/or combustion products into the melt and the geometry of the burnerpanel; if the fuel velocity is too low, the flame temperature may be toolow, providing inadequate temperature in the melter, which is notdesired, and if the fuel flow is too high, flame and/or combustionproducts might impinge on a melter wall or roof, or cause carryover ofmelt into the exhaust, or be wasted, which is also not desired. Bafflesmay be provided extending from the roof, and/or in the melter exhaustconduit, such as in the heat exchange substructure, in order tosafeguard against this. Similarly, oxidant velocity should be monitoredso that flame and/or combustion products do not impinge on an SCM wallor roof, or cause carryover of melt into the exhaust, or be wasted.Oxidant velocities depend on fuel flow rate and fuel velocity, but ingeneral should not exceed about 200 ft./sec at 400 scfh flow rate.

Certain system and method embodiments may be combined with systems andmethods from assignee's co-pending U.S. patent application Ser. No.14/854,271, filed Sep. 15, 2015, for example operating the arrangementof SC burners such that a progressively higher percentage of a totalcombustion flow from the SC burners occurs from SC burners atprogressively downstream positions; or melting using an arrangement oftwo or more SC burners comprises melting with a matrix of at least tworows and at least two columns of SC burners wherein a row spans amajority of the width (W) and a column spans a majority of the length(L) of the SCM, and wherein the operating is selected from the groupconsisting of:

-   -   (a) each SC burner in a first row R1 operates at a rate r₁, each        SC burner in a second row R2 operates at a rate r₂, wherein        r₂>r₁, and    -   (b) if the matrix is a two row by three column matrix or larger,        SC burners on the N and S sides in the first row R1 operate at a        rate r₃, the SC burner in the center (C) of the first row R1        operates at a rate r₄, where r₃>r₄, and SC burners on N and S        sides in a second row R2 operate at a rate r₅ and the SC burner        in the center (C) operates at a rate r₆, where r₅>r₆≥r₄, and        r₅>r₃.

Certain method embodiments may include wherein the melting using anarrangement of two or more SC burners comprises melting with a matrix ofat least two rows and at least two columns of SC burners wherein a rowspans a majority of the width (W) and a column spans a majority of thelength (L) of the SCM, and wherein the operating comprises

-   -   (c) each SC burner in a first row R1 operates at a rate r₁, each        SC burner in a second row R2 operates at a rate r₂, wherein        r₂>r₁.

Certain method embodiments may include wherein the melting using anarrangement of two or more SC burners comprises melting with a matrix ofat least two rows and at least two columns of SC burners wherein a rowspans a majority of the width (W) and a column spans a majority of thelength (L) of the SCM, and wherein the operating comprises

-   -   (d) if the matrix is a two row by three column matrix or larger,        SC burners on the N and S sides in the first row R1 operate at a        rate r₃, and SC burners in the center (C) of the first row        operate at a rate r₄, where r₃>r₄, and SC burners on N and S        sides in a second row R2 operate at a rate r₅ and SC burners in        the center (C) operate at a rate r₆, where r₅>r₆≥r₄, and r₅>r₃.

Certain method embodiments may further comprise measuring concentrationof a tracer compound or element in melt exiting the SCM to verify anincrease in residence time of melt in the SCM compared to residence timeof the melt when all SC burners are firing equally. In certain methods,the tracer compound or element may be selected from the group consistingof ZnO (zinc oxide), SrCO₃ (strontium carbonate), BaCO₃ (bariumcarbonate), and Li₂CO₃ (lithium carbonate), and mixtures andcombinations thereof.

Certain method embodiments may include maximizing mixing and melting inan SCM, the method comprising (or consisting essentially of, orconsisting of):

-   -   (a) melting an inorganic feedstock in an SCM using an        arrangement of two or more SC burners, the SCM having a        length (L) and a width (W), a centerline (C), a north side (N)        and a south side (S); and    -   (b) operating the arrangement of SC burners such that a        progressively lower percentage of total combustion flow rate        from the SC burners occurs from SC burners at progressively        downstream positions from the feed end of the SCM up to a        midpoint (M) of the SCM length (L), and such that a        progressively higher percentage of total combustion flow rate        from the SC burners occurs from SC burners at progressively        downstream positions from the midpoint (M) to the melt exit end        of the SCM.

Certain method embodiments may include wherein the melting using anarrangement of two or more SC burners comprises melting with a matrix ofat least two rows and at least two columns of SC burners wherein a rowspans a majority of the width (W) and a column spans a majority of thelength (L) of the SCM, and wherein the operating the arrangement of SCburners comprises operating the SC burners such that SC burners nearerthe feed end of the SCM have a flow rate r₇, SC burners near the meltexit end have a flow rate r₈, and SC burners near an intersection of Land M have a flow rate r₉, wherein:r ₇ >r ₉r ₈ >r ₉,andr ₈ ≥r ₇.

Certain method embodiments may include wherein the matrix is a 3 row×3column matrix, and SC burners on the N and S sides have flow rategreater than the center SC burners.

Certain method embodiments may include maximizing mixing and temperatureincrease in an SCM, the method comprising (or consisting essentially of,or consisting of):

-   -   (a) melting an inorganic feedstock in an SCM using an        arrangement of two or more SC burners, the SCM having a        length (L) and a width (W), a centerline (C), a north side (N)        and a south side (S); and    -   (b) operating the arrangement of SC burners such that SC burners        in a first zone of the SCM operate fuel lean, and SC burners in        a second zone of the SCM operate fuel rich, and where combustion        products of the SC burners in the first zone mix with combustion        products of the SC burners of the second zone at a position in        the SCM higher than where the lean or rich combustion takes        place.

Certain method embodiments may include wherein the melting using anarrangement of two or more SC burners comprises melting with a matrix ofat least two rows and at least two columns of SC burners wherein a rowspans a majority of the width (W) and a column spans a majority of thelength (L) of the SCM.

Certain method embodiments may include wherein the matrix is a 3 row by3 column matrix and the first zone is at a midpoint (M) of the SCMlength (L), and the second zone is downstream of the midpoint (M) of theSCM length (L).

Certain method embodiments may include wherein the matrix is a 3 row by3 column matrix and the first zone is at a midpoint (M) of the SCMlength (L), and the second zone is upstream of the midpoint (M) of theSCM length (L).

Certain method embodiments may include wherein the first (lean) zone isnear the feed inlet, and the second (fuel rich) zone is immediatelydownstream the first zone, and including feeding small (less than 1 mmAPS) particle size batch material to the SCM in the feed inlet.

Certain method embodiments may include maximizing mixing withoutsubstantially increasing temperature in an SCM, the method comprising(or consisting essentially of, or consisting of):

-   -   (a) melting an inorganic feedstock in an SCM using an        arrangement of two or more SC burners, the SCM having a        length (L) and a width (ON), a centerline (C), a north side (N)        and a south side (S); and    -   (b) operating the arrangement of SC burners such that SC burners        in a first zone of the SCM operate fuel lean, and SC burners in        all other zones of the SCM operate neither fuel rich nor fuel        lean.

Certain method embodiments may include wherein the lean zone is betweenthe feed end of the SCM and the midpoint (M). Certain method embodimentsmay include wherein the lean zone is nearer the melter feed end than anyother melting zone. Certain method embodiments may include wherein thelean zone is between the midpoint (M) and the melter exit end. Certainmethod embodiments may include wherein one or more SC burners isoperated in pulsing mode. Certain method embodiments may include feedinglarge particle size feedstock (at least 10 cm APS) to the SCM inlet end.

Embodiments disclosed herein include:

A: A submerged combustion manufacturing system comprising:

a submerged combustion melter (SCM) equipped with one or more submergedcombustion (SC) burners, the SCM having a length (L) and a width (ON), acenterline (C), a midpoint (M), a sidewall structure having a north side(N) and a south side (S), the sidewall structure connecting a ceilingand a floor of the SCM, and one or more exhaust passages through theceiling, the exhaust passages having an aggregate hydraulic diameter;

the one or more submerged combustion burners configured to dischargecombustion products under a level of material being melted in the melterand create turbulent conditions in substantially all of the materialbeing melted as well as ejected portions of melted material; and

an exhaust structure fluidly connecting the exhaust passage with anexhaust stack, the exhaust structure comprising (or consistingessentially of, or consisting of):

-   -   a liquid-cooled exhaust structure fluidly connected to the        exhaust passage, the liquid-cooled exhaust structure defining a        liquid-cooled exhaust chamber having a first interior surface,        the fluid-cooled exhaust chamber having a cross-sectional area        greater than that of the exhaust stack but less than the melter,    -   the exhaust passage and liquid-cooled exhaust structure        configured to maintain temperature and pressure of the exhaust,        and exhaust velocity through the exhaust passage and the exhaust        structure, at values sufficient to prevent the ejected material        portions of melted material from being propelled out of the        exhaust structure as solidified material, and maintain any        molten materials contacting the first interior surface molten so        that it flows back down the first interior surface back into the        melter.

B: A submerged combustion manufacturing system comprising:

a submerged combustion melter (SCM) equipped with one or more submergedcombustion (SC) burners, the SCM having a length (L) and a width (ON), acenterline (C), a midpoint (M), a sidewall structure having a north side(N) and a south side (S), the sidewall structure connecting a ceilingand a floor of the SCM, and one or more exhaust passages through thesidewall structure, the exhaust passages having an aggregate hydraulicdiameter;

the one or more submerged combustion burners configured to dischargecombustion products under a level of material being melted in the melterand create turbulent conditions in substantially all of the materialbeing melted as well as ejected portions of melted material; and

an exhaust structure fluidly connecting the exhaust passage with anexhaust stack, the exhaust structure comprising (or consistingessentially of, or consisting of):

-   -   a liquid-cooled exhaust structure fluidly connected to the        exhaust passage, the liquid-cooled exhaust structure defining a        liquid-cooled exhaust chamber having a first interior surface,        the fluid-cooled exhaust chamber having a cross-sectional area        greater than that of the exhaust stack but less than the melter,    -   the exhaust passage and liquid-cooled exhaust structure        configured to maintain temperature and pressure of the exhaust,        and exhaust velocity through the exhaust passage and the exhaust        structure, at values sufficient to prevent the ejected material        portions of melted material from being propelled out of the        exhaust structure as solidified material, and maintain any        molten materials contacting the first interior surface molten so        that it flows back down the first interior surface back into the        melter.

C: A submerged combustion manufacturing method comprising:

-   -   melting materials in a submerged combustion melter (SCM)        equipped with one or more submerged combustion (SC) burners, the        SCM having a length (L) and a width (W), a centerline (C), a        midpoint (M), a sidewall structure having a north side (N) and a        south side (S), the sidewall structure connecting a ceiling and        a floor of the SCM, the melter comprising an exhaust passage        through the ceiling;    -   combusting a fuel in the one or more SC burners, the SC burners        discharging combustion products under a level of the material        being melted in the melter and creating turbulent conditions in        substantially all of the material as well as ejected portions of        melted material; and    -   exhausting exhaust material from the melter through an exhaust        structure fluidly connecting the exhaust passage with an exhaust        stack, the exhaust structure comprising (or consisting        essentially of, or consisting of) a liquid-cooled exhaust        structure, the liquid-cooled exhaust structure defining a        liquid-cooled exhaust chamber having a first interior surface,        the liquid-cooled exhaust structure configured to prevent the        ejected material portions of melted material from being        propelled out of the exhaust structure as solidified material,        and maintain any molten materials contacting the first interior        surface molten so that it flows back down the first interior        surface back into the melter.

D: A submerged combustion manufacturing method comprising:

-   -   melting materials in a submerged combustion melter (SCM)        equipped with one or more submerged combustion (SC) burners, the        SCM having a length (L) and a width (W), a centerline (C), a        midpoint (M), a sidewall structure having a north side (N) and a        south side (S), the sidewall structure connecting a ceiling and        a floor of the SCM, the melter comprising and one or more        exhaust passages through the wall structure;    -   combusting a fuel in the one or more SC burners, the SC burners        discharging combustion products under a level of the material        being melted in the melter and creating turbulent conditions in        substantially all of the material as well as ejected portions of        melted material; and    -   exhausting exhaust material from the melter through an exhaust        structure fluidly connecting the one or more exhaust passages        with an exhaust stack, the exhaust structure comprising (or        consisting essentially of, or consisting of) one or more        liquid-cooled exhaust structures, the one or more liquid-cooled        exhaust structures defining one or more liquid-cooled exhaust        chambers having a first interior surface, the liquid-cooled        exhaust structures configured to prevent the ejected material        portions of melted material from being propelled out of the        exhaust structure as solidified material, and maintain any        molten materials contacting the first interior surface molten so        that it flows back down the first interior surface back into the        melter.

Each of the embodiments A, B, C, and D may have one or more of thefollowing additional elements in any combination: Element 1: the systemand method may further comprise a gas-cooled exhaust structure fluidlyconnecting the liquid-cooled exhaust structure and the exhaust stack,the gas-cooled exhaust structure defining a gas-cooled exhaust chamberhaving a second interior surface, the gas-cooled exhaust structureconsisting of a metal layer forming the second interior surface, themetal layer having one or more gas-cooled external surfaces, thegas-cooled exhaust structure devoid of refractory or other lining.Element 2: systems and methods wherein the gas-cooled exhaust chamberhas a cross-sectional area substantially equal to the cross-sectionalarea of the liquid-cooled exhaust chamber. Element 3: systems andmethods comprising a feed inlet in a feed end of the wall structure, amolten product outlet in an exit end of the wall structure, wherein theexhaust passage through the ceiling is positioned substantiallycentrally between the feed and exit ends. Element 4: systems and methodswherein the exhaust passage and the liquid-cooled exhaust chamber have across-sectional area configured to produce exhaust velocity of 25ft./min. or less through the exhaust passage and liquid-cooled exhaustchamber. Element 5: systems and methods wherein the submerged combustionburners are configured to discharge combustion products primarilynon-laterally under the level of material being melted in the melter.Element 6: systems and methods wherein the submerged combustion burnersare configured to discharge combustion products primarily verticallyunder the level of material being melted in the melter. Element 7:systems and methods wherein the wall structure comprises a feed endwall, an exit end wall, and two side walls, with each side wallconnected to both the feed end wall and the exit end wall. Element 8:systems and methods wherein the liquid-cooled exhaust structure isconstructed of metal having service temperature higher than temperatureof the exhaust materials. Element 9: systems and methods wherein thegas-cooled exhaust structure is constructed of metal having servicetemperature higher than temperature of the exhaust materials. Element10: systems and methods wherein the metal layer is one or moreaustenitic nickel-chromium super alloys, and the air-cooled surfaces aresteel. Element 11: systems and methods wherein the liquid-cooled exhauststructure is configured for cooling using a liquid selected from thegroup consisting of water, organic liquids, inorganic liquids, andcombinations thereof. Element 12: systems and methods comprising an airinspirator fluidly connecting the liquid-cooled exhaust barrier and theexhaust stack. Element 13: systems and methods wherein the airinspirator is selected from the group consisting of one or moreadjustable panels, and one or more adjustable hoods. Element 14: systemsand methods wherein the exhaust structure has a cross-sectional shapeselected from the group consisting of rectangular, round, oval,trapezoidal, triangular, U-shaped, quadrangular, hexagonal, octagonal,and parabolic. Element 15: systems and methods wherein the exhaustpassage is substantially centrally located between a feed end and anexit end of the melter, and the exhausting of the exhaust materialthrough the exhaust structure comprises exhausting the exhaust materialsubstantially centrally between the feed end and the exit end of themelter. Element 16: systems and methods comprising inspiring air intothe exhaust material through an air inspirator fluidly connecting theliquid-cooled exhaust structure and the exhaust stack. Element 17:systems and methods comprising adjusting the air inspirator to allowmore or less air to enter the exhaust stack. Element 18: systems andmethods comprising feeding small (less than 1 mm APS) particle sizebatch material to the SCM into at least one feed inlet port. Element 19:systems and methods comprising feeding large particle size feedstock (atleast 10 cm APS) into the SCM through one or more auxiliary inlet ports.

Although only a few exemplary embodiments of this disclosure have beendescribed in detail above, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this disclosure, and these modification are consideredfurther Elements in accordance with the previous paragraph that may becombined with all other embodiments. For example, the heat transferstructures and methods described herein may be counter-current,cross-current, or co-current, or combination thereof in any particularembodiment (for example, a first liquid-cooled section where liquid heattransfer fluid flows generally counter-current to melter exhaust,followed by a second liquid-cooled section where a second (or the same)liquid heat transfer fluid flows generally co-current to melter exhaust;or for example, a liquid-cooled section that is counter-current,followed by a gas-cooled section that is co-current). One, two, or morethan two different liquid heat transfer fluids may be used in aliquid-cooled section (for example water in a first section, and anethylene glycol mixture in a second section). One, two, or more than twodifferent gas heat transfer fluids may be used in a gas-cooled section(for example water in a first section, and an ethylene glycol/watermixture in a second section). Accordingly, all such modifications areintended to be included within the scope of this disclosure as definedin the following claims. In the claims, no clauses are intended to be inthe means-plus-function format allowed by 35 U.S.C. § 112, Section F,unless “means for” is explicitly recited together with an associatedfunction. “Means for” clauses are intended to cover the structures,materials, and/or acts described herein as performing the recitedfunction and not only structural equivalents, but also equivalentstructures.

What is claimed is:
 1. A submerged combustion manufacturing systemcomprising: a submerged combustion melter (SCM) equipped with one ormore submerged combustion (SC) burners, the SCM having a length (L) anda width (W), a centerline (C), a midpoint (M), a sidewall structurehaving a north side (N) and a south side (S), the sidewall structureconnecting a ceiling and a floor of the SCM, and one or more exhaustpassages through the ceiling, the one or more exhaust passages having anaggregate hydraulic diameter; the one or more submerged combustionburners configured to discharge combustion products under a level ofmaterial being melted in the SCM and create turbulent conditions insubstantially all of the material being melted as well as ejectedportions of melted material; and an exhaust structure fluidly connectingthe one or more exhaust passages with an exhaust stack, the exhauststructure comprising: a liquid-cooled exhaust structure of height H1fluidly connected to the one or more exhaust passages, the liquid-cooledexhaust structure defining a liquid-cooled exhaust chamber having afirst interior surface, the liquid-cooled exhaust chamber having across-sectional area greater than that of the exhaust stack but lessthan the SCM, the one or more exhaust passages and the liquid-cooledexhaust structure configured to maintain temperature and pressure ofexhaust materials from the SCM, and exhaust velocity of the exhaustmaterials from the SCM through the liquid-cooled exhaust structure, atvalues sufficient to prevent the ejected portions of melted materialfrom being propelled out of the liquid-cooled exhaust structure and intothe exhaust stack as solidified material, and maintain any moltenmaterials contacting the first interior surface molten so that it flowsback down the first interior surface back into the SCM, and a gas-cooledexhaust structure of height H7 fluidly connecting the liquid-cooledexhaust structure and the exhaust stack, the gas-cooled exhauststructure defining a gas-cooled exhaust chamber having a second interiorsurface, the gas-cooled exhaust structure consisting of a metal layerforming the second interior surface, the metal layer having one or moregas-cooled external surfaces, the gas-cooled exhaust structure devoid ofrefractory or other lining, wherein H1 is greater than or equal to H7,and H7 is not
 0. 2. The system of claim 1 wherein the gas-cooled exhaustchamber has a cross-sectional area substantially equal to thecross-sectional area of the liquid-cooled exhaust chamber.
 3. The systemof claim 1 comprising a feed inlet in a feed end of the sidewallstructure, a molten product outlet in an exit end of the sidewallstructure, wherein the one or more exhaust passages through the ceilingare positioned substantially centrally between the feed end and the exitends.
 4. The system of claim 1 wherein the one or more exhaust passagesand the liquid-cooled exhaust chamber have a cross-sectional areaconfigured so that the exhaust velocity of the exhaust materials is 25ft./min. or less through the one or more exhaust passages and theliquid-cooled exhaust chamber.
 5. The system of claim 1 wherein the oneor more submerged combustion burners are configured to discharge thecombustion products primarily non-laterally under the level of thematerial being melted in the SCM.
 6. The system of claim 1 wherein theone or more submerged combustion burners are configured to discharge thecombustion products primarily vertically under the level of the materialbeing melted in the SCM.
 7. The system of claim 1 wherein the sidewallstructure comprises a feed end wall, an exit end wall, and two sidewalls, with each of the two side walls connected to both the feed endwall and the exit end wall.
 8. The system of claim 1 wherein theliquid-cooled exhaust structure is constructed of metal having a servicetemperature higher than a temperature of the exhaust materials.
 9. Thesystem of claim 1 wherein the gas-cooled exhaust structure isconstructed of metal having service a temperature higher than atemperature of the exhaust materials.
 10. The system of claim 9 whereinthe metal is one or more austenitic nickel-chromium super alloys, andthe one or more gas-cooled external surfaces are steel.
 11. The systemof claim 1 wherein the liquid-cooled exhaust structure is configured forcooling using a liquid selected from the group consisting of water,organic liquids, inorganic liquids, and combinations thereof.
 12. Thesystem of claim 1 comprising an air inspirator fluidly connecting theliquid-cooled exhaust structure and the exhaust stack.
 13. The system ofclaim 12 wherein the air inspirator is selected from the groupconsisting of one or more adjustable panels, and one or more adjustablehoods.
 14. The system of claim 1 wherein the exhaust structure has across-sectional shape selected from the group consisting of rectangular,round, oval, trapezoidal, triangular, U-shaped, quadrangular, hexagonal,octagonal, and parabolic.
 15. A submerged combustion manufacturingsystem comprising: a submerged combustion melter (SCM) equipped with oneor more submerged combustion (SC) burners, the SCM having a length (L)and a width (W), a centerline (C), a midpoint (M), a sidewall structurehaving a north side (N) and a south side (S), the sidewall structureconnecting a ceiling and a floor of the SCM, and one or more exhaustpassages through the sidewall structure, the one or more exhaustpassages having an aggregate hydraulic diameter; the one or moresubmerged combustion burners configured to discharge combustion productsunder a level of material being melted in the SCM and create turbulentconditions in substantially all of the material being melted as well asejected portions of melted material; and an exhaust structure fluidlyconnecting the one or more exhaust passages with an exhaust stack, theexhaust structure comprising: a liquid-cooled exhaust structure ofheight H1 fluidly connected to the one or more exhaust passages, theliquid-cooled exhaust structure defining a liquid-cooled exhaust chamberhaving a first interior surface, the liquid-cooled exhaust chamberhaving a cross-sectional area greater than that of the exhaust stack butless than the SCM, the one or more exhaust passages and theliquid-cooled exhaust structure configured to maintain temperature andpressure of exhaust materials from the SCM, and exhaust velocity of theexhaust materials from the SCM through the liquid-cooled exhauststructure, at values sufficient to prevent the ejected portions ofmelted material from being propelled out of the liquid-cooled exhauststructure and into the exhaust stack as solidified material, andmaintain any molten materials contacting the first interior surfacemolten so that it flows back down the first interior surface back intothe SCM, and a gas-cooled exhaust structure of height H7 fluidlyconnecting the liquid-cooled exhaust structure and the exhaust stack,the gas-cooled exhaust structure defining a gas-cooled exhaust chamberhaving a second interior surface, the gas-cooled exhaust structureconsisting of a metal layer forming the second interior surface, themetal layer having one or more gas-cooled external surfaces, the metallayer forming the second interior surface devoid of refractory or otherlining, wherein H1 is greater than or equal to H7, and H7 is not
 0. 16.The system of claim 15 wherein the one or more exhaust passages and theliquid-cooled exhaust chamber have a cross-sectional area configured sothat the exhaust velocity of the exhaust materials is 25 ft./min. orless through the liquid-cooled exhaust chamber.